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Study on the Microstructure and Compression of Composite Metal Foam Core Sandwich Panels

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Abstract

Stainless steel composite metal foam core sandwich panels (SS-CMF-CSP) were manufactured in large-scale panels and tested under quasi-static compression. Stainless steel face sheets were attached to the SS-CMF core using two methods: diffusion and adhesive bonding. Scanning electron microscope imaging revealed grain growth in both the matrix and sphere wall for the diffusion-bonded sandwich panels. The face sheets were found to not greatly affect the deformation of the SS-CMF core under compression. However, the diffusion-bonded SS-CMF-CSP yielded a stronger product primarily due to microstructural changes that occur during the diffusion bonding heat cycle within the SS-CMF core. The diffusion-bonded SS-CMF-CSP had a plateaus stress and densification stress 17 and 10 pct higher than its baseline SS-CMF, respectively. The large-scale manufacturing was improved, and additional samples were tested with a yield and plateau strength 75 to 80 pct higher than the initial SS-CMF samples. The improved diffusion-bonded SS-CMF-CSP showed similar strengthening, with a plateau stress 16 pct higher than its base SS-CMF. Finite element analysis was completed using IMPETUS Afea that advances the current modeling of SS-CMF and was found to be in good agreement with the experimental findings.

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Acknowledgments

This research was supported by the Department of Transportation (DOT) Pipeline and Hazardous Materials Safety Administration (PHMSA) under Project Number #DTPH5616C00001. The authors would also like to acknowledge MDG solutions Inc. for their efforts with the modeling work.

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  1. Advanced Materials Research Lab, Department of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, NC, 27695, USA

    Jacob Marx & Afsaneh Rabiei

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  1. Jacob Marx
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  2. Afsaneh Rabiei
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Correspondence to Afsaneh Rabiei.

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Manuscript submitted April 22, 2020.

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Marx, J., Rabiei, A. Study on the Microstructure and Compression of Composite Metal Foam Core Sandwich Panels. Metall Mater Trans A 51, 5187–5197 (2020). https://doi.org/10.1007/s11661-020-05964-1

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